Self-supporting film with a heat-sealable coating of an ionic copolymer of an olefin and carboxylic acid with metal ions distributed throughout



United States Patent 3,355,319 SELF-SUPPORTING FILM WITH A HEAT-SEALA- BLE COATING OF AN IONIC COPOLYMER OF AN OLEFIN AND CARBOXYLIC ACID WITH METAL IONS DISTRIBUTED THROUGHOUT Richard Watkin Rees, Wilmington, Del., assignor to E. 1. du Pont de Nemours and Company, Wilmington, Del., a corporation of Delaware No Drawing. Filed Mar. 17, 1964, Ser. No. 352,658 8 Claims. (Cl. 117-122) ABSTRACT OF THE DISCLOSURE Heat-sealable film structure of organic thermoplastic polymeric materials such as polyolefins and polyamides are provided having a heat-scalable coating of an ionic copolymer of a-olefins and alpha, beta-ethylenically unsaturated monocarboxylic acids containing uniformly distributed therethrough a metal ion having an ionized valence of 1-3.

The present application is a continuation-in-part of copending application Serial No. 271,477, filed April 8, 1963, now U.S. Patent No. 3,264,272, which in turn derives from application Serial No. 135,147, filed Aug. 31, 1961, now abandoned. The present invention relates to novel structures of hydrocarbon polymers, and, more particularly to self-supporting film structures having heatsealable polymeric coatings which contain ionic crosslinks.

The crosslinking of hydrocarbon polymers is well known in the art. Thus, polymeric hydrocarbon elastomers, such as natural rubber, are crosslinked or vulcanized by the use of sulfur, which reacts with the carbon of the unsaturated bonds in polymer molecules to form a bridge between two molecules so that one polymer molecule is covalently bonded to a second polymer molecule. If sufiicient crosslinks of this type occur in the polymeric hydrocarbon, all molecules are joined in a single giant molecule. The characteristic property of a crosslinked polymer is its intractibility above the softening point or melting point normally observed in the uncrosslinked base polymer.-Thus, whereas the uncrosslinked polymer has a marked softening point or melting point above which the polymer is fluid and deformable, the crosslinked polymer retains its shape and will tend to return to that shape when deformed at all temperatures at which the polymer is stable and cannot be permanently deformed. Although once crosslinked'the polymer is no longer fabricable, except possibly by machining, crosslinked polymers have found wide utility because of the significant improvement in the physical properties obtained by crosslinking. Thus, by vulcanizing rubber, elasticity, impact resistance, flexibility, thermal stability and many other properties are either introduced or improved. The crosslinking of non-elastomeric polymers increases the toughness, abrasion resistance and, particularly, the upper use temperatures of the material.

In addition to the vulcanization of diene hydrocarbon polymers using sulfur, other methods of crosslinking hydrocar-bon polymers which do not require a double bond and which do not use sulfur have been developed. Thus, saturated hydrocarbon polymers and, in particular, polyethylene, are crosslinked by reactions resulting from the addition of a peroxide to the polymer at elevated temperatures. Peroxides decompose to form free radicals which in turn attack the polymer chain to form crosslinking sites which then react to form crosslinks. Irradiation of polyethylene also results in a crosslinked product by substantially the same mechanism except that the free radicals are generated by decomposition of the polymer 3,355,319 Patented Nov. 28, 1967 itself. By either method, however, a product is obtained which is intractible and can not be further fabricated by techniques normally used in the fabrication of polyethylene such as melt extrusion or injection molding. The improvement obtained in the solid state properties of a hydrocarbon polymer by crosslinking have, therefore, been always combined with a loss in fabricability as a result of which crosslinked hydrocarbon polymers, with the exception of elastomeric hydrocarbon polymers, have found little commercial success as compared to the uncrosslinked hydrocarbon polymers. Furthermore, crosslinking reduces the crystallinity of saturated hydrocarbon polymers, thereby decreasing the stiffness and rigidity of the product.

In the development of films for various applications, it has been necessary in many cases to provide means for readily sealing such films into packages and to improve such films in other respects such as abrasion resistance, resistance to greases and permeation of undesired vapors. Commonly, this is achieved by applying a coating of a suitable resin on one or more of the film surfaces. In many instances, such a coated film does not have a satisfactory balance of properties. In particular, it has been difficult to find suitable resin coatings which would impart toughness characteristics to the films such as good resistance to abrasion, resistance to penetration of undesired liquids and vapors and at the same time be readily heat-scalable over a range of temperatures and particularly at a low enough temperature to be readily adaptable for high speed packaging operations.

It is an object of the present invention to provide coatings of modified hydrocarbon polymers for self-supporting organic thermoplastic film structures, which coatings possess good toughness characteristics, high resistance to permeation of organic liquids and vapors and ready heatsealability. Other objects will become apparent hereinafter.

According to the present invention there is provided an article of manufacture comprising a heat-scalable film structure of a base layer of a self-supporting film of organic thermoplastic polymeric material having a heatsealable coating on at least one surface thereof of an ionic copolymer selected from the class consisting of direct copolymers of: cc-OlCfiIlS having the general formula RCH=CH Wherein R is a radical selected from the class consisting of hydrogen and alkyl radicals having from 1 to 8 carbon atoms, the olefin content of said copolymer being at least 50 mol percent based upon said copolymer,

and an alpha, beta-ethylenically unsaturated monocarboxylic acid, the acid monomer content of said copolymer being from 5 to 25 mol percent based upon the copolymer,

said copolymer having a melt-index between about 0.5 and about 40 and containing uniformly distributed throughout said copolymer a metal ion having an ionized valence of 1 to 3 inclusive, wherein at least 10 percent of said monovalent carboxylic acid copolymer are neutralized by said metal ion and exist in an ionic state.

As indicated, the a-OlCfiIlS employed in the copolymer are m-olefins which have the general formula RCH=CH where R is either a hydrogen or an alkyl group having preferably from 1 to 8 carbon atoms. Thus, suitable olefins include ethylene, propylene, butene-l, pentene-l, hexene-l, heptene-l, 3-methylbutene-1, 4-methylpentene- 1, etc. Although u-olefins having higher carbon numbers can be employed in the present invention, they are not materials which are readily obtained or available. The concentration of the polymerized u-olefin in the copolymer is at least 50 mol percent and is preferably greater than mol percent.

The second essential component of the base copolymer is derived from an u,fl-ethylenically unsaturated carboxylic acid group-containing monomer having preferably from 3 to 8 carbon atoms. Examples of such monomers are acrylic acid, methaerylic acid, ethacrylic acid, itaconic acid, maleic acid, fumaric acid, monoesters of said dicarboxylic acids, such as methyl hydrogen malcate, methyl hydrogen fumarate, ethyl hydrogen fumarate and maleic anhydride. Although maleic anhydride is not a carboxylic acid in that it has no hydrogen attached to the carboxyl groups, it can be considered an acid for the purposes of the present invention because of its chemical reactivity being that of an acid. Similarly, other 05,8- monoethylenically unsaturated anhydrides of carboxylic acids can be employed. As indicated, the concentration of acidic monomers in the copolymer is from 0.2 mol percent to 25 mol percent, and, for film application, preferably from to 25 mol percent of a mono-basic carboxylic acid and most preferably, from 10 to 20 mol percent.

The base copolymers employed in forming the ionic copolymers of the present invention may be prepared in several ways. Thus, the copolymers may be obtained by the copolymerization of a mixture of the olefin and the carboxylic acid monomer. This method is preferred for the copolymers of ethylene employed in the present invention. Methods employed for the preparation of ethylene carboxylic acid copolymers have been described in the literature. In a preferred process, a mixture of the two monomers is introduced into a polymerization environment maintained at high pressures, 50 to 3000 atmospheres, and elevated temperatures, 150 to 300 C., together with a free radical polymerization initiator such as a peroxide. An inert solvent for the system, such as water or benzene, may be employed, or the polymerization may be substantially a bulk polymerization.

Copolymers of ot-olefins with carboxylic acids may also be prepared by copolymerization of the olefin with an a,/i-ethylenically unsaturated carboxylic acid derivative which subsequently or during copolymerization is reacted either completely or in part to form the free acid. Thus, hydrolysis, saponification or pyrolysis may be employed to form an acid copolymer from an ester copolymer.

Although ionic crosslinks can also be formed with copolymers obtained by grafting an u,,8-ethylenically unsaturated carboxylic acid monomer to a polyolefin base, such copolymers do not show the degree of improvement obtained with copolymers formed by direct copolymerization, i.e., direct copolymers. To insure uniform ionic crosslinking throughout the copolymer, it is essential to employ a copolymer containing the earboxylic acid groups randomly distributed over all molecules. Such random distribution is best obtained by direct copolymerization. Graft copolymers which contain a third nonreactive monomer grafted to the carboxylic acid 00- polymer are, of course, satisfactory.

The copolymers employed to form ionic copolymers which are useful as plastics are preferably of high molecular weight in order to achieve the outstanding combination of solid state properties of crosslinked polyolefins with the melt fabricability of uncrosslinked polyolefins. Although the mechanical properties of a low molecular weight copolymer are improved by the process of the present invention, the resulting product does not exhibit such mechanical properties as are markedly superior to the same unmodified copolymer, when of high molecular weight. The molecular weight of the copolymers useful as base resins is most suitably defined by melt index, a measure of viscosity, described in detail in ASTMD- 1238-57T. The melt index of copolymers employed in the formation of ionic copolymers which are useful as plastics is preferably in the range of 0.1 to 1000 g./10 min. and, more particularly, in the range of 1.0 to 100 g./ 10 min. For application as a thermoplastic film coating, a melt index in the range of 0.5 to 40 g./ 10 min. is preferred, most preferably 0.5 to 15 g./10 min. However,

it should be pointed out that low molecular weight copolymers result in ionic copolymers which, although not suitable as plastics, are outstanding adhesives and laminating resins.

The copolymer base need not necessarily comprise a two component polymer. Thus, although the olefin content of the copolymer should be at least 50 mol percent, more than one olefin can be employed to provide the hydrocarbon nature of the copolymer base. Additionally, any third copolymerizable monomer can be employed in combination with the olefin and the carboxylic acid comonomer. The scope of base copolymers suitable for use in the present invention is illustrated by the following examples: Ethylene/acrylic acid copolymers, ethylene/methacrylic acid copolymers, ethylene/itaconic acid copolymers, ethylene/methyl hydrogen maleate copolymers, ethylene/maleic acid copolymers, ethylene/acrylic acid/methyl methacrylate copolymers, ethylene/methacrylic acid/ethyl acrylate copolymers, et'hylene/itaconic acid/methyl methacrylate copolymers, ethylene/methyl hydrogen maleate/ethyl aerylate copolymers, ethylene/ methacrylic acid/ vinyl acetate copolymers, ethylene/ acrylic acid/vinyl alcohol copolymers, ethylene/propylene/acrylic acid copolymers, ethylene/styrene/acrylic acid copolymers, ethylene/methacrylic acid/acrylonitrile copolymers, ethylene/fumarie acid/vinyl methyl ether copolymers, ethylene/vinyl chloride/ acrylic acid copolymers, ethylene/vinylidene chloride/acrylic acid copolymers, ethylene/vinyl fiuoride/methacrylic acid copolymers, and ethylene/chlorotrifiuoroethylene/methacrylic acid copolymers.

The copolymers may also, after polymerization but prior to ionic crosslinking, be further modified by various reactions to result in polymer modifications which do not interfere with the ionic erosslinking. Halogenation of an olefin acid copolymer is an example of such polymer modification.

The preferred base copolymers, however, are those obtained by the direct copolymerization of ethylene with a monoearboxylie acid comonomer.

The ionic copolymers of the present invention are obtained by the reaction of the described copolymer base with an ionizable metal compound. This reaction is referred to herein as neutralization. The reaction mechanism involved in the formation of the ionic copolymers and the exact structure of the copolymers are at the present time not completely understood. However, a comparison of the infrared spectrum of the copolymer base with that of the ionic copolymer shows the appearance of an absorption band at about 6.4 microns which is characteristic of the ionized carboxyl group, COO, a decrease in the erystallinity band at 13.7 microns and a substantial decrease, depending on the degree of neutralization, of a band at 106 microns, characteristic of the un-ionized carboxyl group, COOH. It is consequently deduced that the surprising properties of ionic copolymers are the result of an ionic attraction between the metal ion and one or more ionized carboxylic acid groups.

This ionic attraction results in a form of cross-linking which occurs in the solid state. However, when molten and subjected to the shear stresses which occur during melt fabrication, the ionic crosslinks of these polymers are ruptured and the polymers exhibit melt fabricability essentially the same as that of the linear base copolymer. On cooling of the melt and in the absence of the shear stress occurring during fabrication, the crosslinks, because of their ionic nature, are reformed and the solidified copolymer again exhibits the properties of a crosslinked material.

The change in properties resulting from the neutralization of the base copolymer to the ionic copolymer is greatly influenced by the degree of neutralization and, therefore, the number of ionic crosslinks and the nature of the crosslink involved. Although an improvement in solid state properties is obtained with even a small percentage of the acid groups neutralized, in general, a noticeable improvement is observed only after 10 percent of the acid groups have been neutralized. However, to obtain the optimum solid state properties which are derivable from ionic copolymers, the number of cross-links should be sufficient to form an infinite network of crosslinked polymer chains. This, of course, not only depends on the degree of neutralization, but also on the number of crosslinking sites and the molecular weight of the base copolymer. In general, it is found that base copolymers having molecular weights as measured by melt index of l to 5 g./l min. and a monocarboxylic acid concentration of to percent show optimum solid state properties upon 50 to 80 percent neutralization. The degree of neutralization can be decreased as the molecular weight of the copolymer base is increased or as the acid content of the copolymer base is increased without significantly changing the solid state properties. In general, no substantial further improvement in solid state properties is observed if the crosslinking is continued beyond the point at which an infinite network is formed. However, the shear stress necessary to break the ionic crosslinks and, thus, make the copolymer melt fabricable is steadily increased with an increasing number of crosslinks beyond that necessary to achieve an infinite network.

The melt fabricability of the ionic copolymer is affected not only by the number of crosslinks, but to a much greater degree, is affected by the nature of the crosslink. The combination of certain types of acid copolymers with certain metal ions results in intractible materials which do not lend themselves to melt fabrication. Thus, it was found that base copolymers with dicarboxylic acid comonomers, even those in which one acid radical has been esterified, when neutralized with metal ions which have two or more ionized valences, result in intractible ionic copolymers at the level of neutralization essential to obtain significant improvement in solid state properties. Similarly, base copolymers with monocarboxylic acid comonomers result in intractible ionic copolymers when neutralized to the indicated degree with metal ions which have four or more ionized valences. It is believed that the nature of the ionic bond in these instances is too strong to be suitable for the formation of ionic copolymers which exhibit solid state properties of crosslinked resins and melt properties of uncrosslinked resins.

Metal ions which are suitable in forming the ionic copolymers of the present invention can be divided into two categories, uncomplexed metal ions and complexed metal ions. In the uncomplexed metal ions the valence of the ion corresponds to the valence of the metal. These metal ions are obtained from the commonly known and used metal salts. The complexed metal ions are those in which the metal is bonded to more than one type of salt group, at least one of which is ionized and at least one of which is not. Since the formation of the ionic copolymers requires only one ionized valence state, it -will be apparent that such complexed metal ions are equally well suited in the present invention. The term metal ion having one or more ionized valence states means a metal ion having the general formula Me+ X Where n is the ionic charge and is at least one, X is a nonionized group and n+m equal the valence of the metal. The utility of complexed metal ions employed in the formation of ionic copolymers corresponds in their ionized valences to those of the uncomplexed metal ions. The monovalent metals are, of course, excluded but higher valent metals may be included depending on how many metal valences are complexed and how many can be ionized. The preferred complexed metal ions are those in which all but one metal valence are complexed and one is readily ionized. Such compounds are in particular the mixed salts of very weak acids, such as oleic and stearic acid, with ionizable acids, such as formic and acetic acid.

The uncomplexed metal ions which are suitable in forming the ionic copolymers of the present invention, therefore, comprise for the a-olefin-monocarboxylic acid copolymers, mono-, diand trivalent ions of metals in Groups I, H, III, IV-A and VIII of the Periodic Table of Elements (see p. 392, Handbook of Chemistry and Physics, Chemical Rubber Publishing Co., 37th ed.). Uncom plexed monovalent metal ions of the metals in the stated groups are also suitable in forming the ionic copolymers of the present invention with copolymers of olefins and ethylenically unsaturated dicarboxylic acids. Suitable monovalent metal ions are Nat, K Li' Cs+, Ag+, Hg+ and Cu+. Suitable divalent metal ions are Be, Mg, Ca Sr+ Ba+ Cu+ Cd+ Hg+ Sn+ Ph Fe+ Co Ni+ and Zn. Suitable trivalent metal ions are Al+ Sc Fe+ and Y.

The preferred metals, regardless of the nature of the base copolymer are the alkali metals. These metals are preferred because they result in ionic copolymers having the best combination of improvement in solid state properties with retention of melt fa'bricability. It is not essential that only one metal ion be employed in the formation of the ionic copolymers and more than one metal ion may be preferred in certain applications.

The quantity of ions employed or the degree of neutralization will differ with the degree of solid property change and the degree of melt property change desired. In general, it was found that the concentration of the metal ion should be at least such that the metal ion neutralizes at least 10 percent of the carboxylic acid groups in order to obtain a significant change in properties. As explained above, the degree of neutralization for optimum properties will vary with the acid concentration and the molecular weight of the copolymer. However, it is generally desirable to neutralize at least 50 percent of the acid groups. Thedegree of neutralization may be measured by several techniques. Thus, infrared analysis may be employed and the degree of neutralization calculated from the changes resulting in the absorption bands. Another method comprises the titration of a solution of the ionic copolymer with a strong base. In general, it was found that the added metal ion reacts stoichiometrically with the carboxylic acid in the polymer up to percent neutralizations. Small excess quantities of the crosslinking agent are necessary to carry the neutralization to com pletion. However, large excess quantities of the crosslinking agent do not add to the properties of the ionic copolymer of the present invention, since once all carboxylic acid groups have been ionically crosslinked, no further crosslinks are formed.

The crosslinking of the ionic copolymer is carried out by the addition of a metal compound to the base copolymer. The metal compound which is employed must have at least one of its valences satisfied by a group which is substantially ionized in water. The necessary ionization is determined by the water solubility of the metal when bonded solely to the ionizable salt group. A compound is considered water-soluble for the purposes of the present invention if it is soluble in water at room temperature to the extent of 2 weight percent. This requirement is explained as separating those ionic compounds which are capable of exchanging a metal ion for the hydrogen ion of the carboxylic acid group in the copolymer from those which do not interact with the acid. The second requirement of the metal compound employed to give rise to the ionic crosslink is that the salt radical reacting with the hydrogen of the carboxylic acid group must form a compound which is removable from the copolymer at the reaction conditions. This requirement is essential to obtain the carboxylic acid group of the coploymer in ionic form and, furthermore, to remove the salt radical from the copolymer so that the attraction between the ionized carboxylic acid group of the copolymer and the metal ion is not overshadowed by the attraction of the metal ion and its original salt radical. With these two parameters it is, therefore, possible to determine those metal compounds which form metal ions having the required ionic valences.

Although the foregoing limits delineate metal compounds suitable in forming metal ions in the acid copolymers which result in ionic crosslinks, certain types of compounds are preferred because of their ready availability and ease of reaction. Preferred metal salts includes formates, acetates, hydroxides of sufficient solubility, methoxides, ethoxides, nitrates, carbonates and bicarbonates. Metal compounds which are generally not suitable in resulting in ionic crosslinks include in particular metal oxides because of their lack of solubility and the fact that such compounds form intractible compositions, metals salts of fatty acids which either are not sufficiently soluble or form compounds with the hydrogen of the acid which can not be removed and metal coordination compounds which lack the necessary ionic character.

As set forth hereinabove, in addition to uncomplexed metal ions, complexed metal ions which contain the necessary ionic valences bonded to groups meeting the aforesaid requirements can be employed. In such cases the group which does not ionize or is not removed has no effect on the ability of the ionizing group to be removed and the resulting metal ion to cause the ionic crosslinking. Thus, whereas zinc distearate of calcium dioleate are ineffective to cause ionic crosslinking such mixed metal salts as zinc stearate-acetate or calicum oleate-acetate are effective crosslinking agents.

It is not essential that the metal compound be added as such, but it is possible to form the metal compound in situ from components which react with each other in the desired manner in the polymer environment. Thus, it is possible to add a metal oxide to the base copolymer then add an acid such as acetic acid in the proper proportion and form the ionic compound, i.e., the metal acetate, while the polymer is milled.

The crosslinking reaction is carried out under conditions which allow for a homogeneous uniform distribution of the crosslinking agent in the base copolymer. No particular reaction conditions are essential except that the conditions should permit the removal of the hydrogen-salt radical reaction product which is preferably accomplished by volatilization. Since the homogeneous distribution of the crosslinking agent and the necessary volatilization of the hydrogen-salt radical reaction product is difficult at room temperature, elevated temperatures are generally employed. More specifically, the crosslinking reaction is carried out either by melt blending the polymer with the crosslinkingmetal compound, which preferably is employed in solution, or by adding the crosslinking agent, directly or in solution, to a solution of the copolymer base and then, on reaction, precipitating and separating the resulting polymer. On these techniques, the first is greatly preferred because of its relative simplicity. It is to be understood, however, that the specific technique employed is not critical as long as it meets the specific requirements set forth above. The course of neutralization, i.e., the degree to which the metal ion is ionically linked with the carboxylate ion and the carboxylate hydrogen has reacted with the metal compound anion and has been removed, can be readily followed by infrared spectroscopy through measurement of the nonionized and ionized carboxylate groups.

The following examples further illustrate the methods employed in forming the ionic copolymers of the present invention. Neutralization as used in the examples is based on the percentage of carboxylate ions as compared to carboxylic acid groups.

Example I A 500 g. sample of an ethylene/methacrylic acid copolymer, containing 10 weight percent of methacrylic acid and having a melt index of 5.8 g./ 10 min. (ASTM- D-123'8-57T) was banded on a 6 inch rubber mill at 150 C. After the copolymer had attained the mill temperature, 24 g. of sodium methoxide dissolved in 100 ml. of methanol was added to the copolymer over a period of 5 minutes as working of the copolymer on the mill was continued. Melt blending of the composition was continued for an additional 15 minutes during which time the initially soft, fluid melt became stiff and rubbery on the mill. However, the polymer could still be readily handled on the mill. The resulting product was found to have a melt index of less than 0.1 g./ 10 minutes and resulted in transparent, as compared to opaque for the copolymer base, moldings of greatly improved tensile prop erties.

Example II To a solution of 50 g. of an ethylene/methacrylic acid copolymer containing 10 weight percent of the methacrylic acid and having a melt index of 5.8 g./ 10 minutes in 250 ml. of xylene maintained at a temperature of C. was added 3 g. of strontium hydroxide dissolved in 50 ml. of water. Gelation followed immediately. The product was recovered by precipitation with methanol and washed thoroughly with water and acetone. The final dry product was found to have a metal index of 0.19 g./ 10 minutes and resulted in glass clear moldings.

Example III To 50 g. of an ethylene/methacrylic acid copolymer containing 10 weight percent of methacrylic acid and having a melt index of 5.8 g./ 10 minutes milled at a temperature of to C. on a 6 inch rubber mill was added gradually 6.3 g. of magnesium acetate (x 4H O) in 25 ml. of water. Milling was continued for 15 minutes at which time the evolution of acetic acid had ceased. The product had a melt index of 0.12 g./ 10 minutes and resulted in clear, resilient moldings.

Example IV To 50 g. of an ethylene/itaconic acid copolymer having a melt index of 9 g./ 10 minutes and containing 3 percent by weight of the copolymer of itaconic acid was gradually added 3 g. of sodium hydroxide in 20 m1. of water while the polymer was being worked on a 6 inch rubber mill at a temperature of C. Upon addition of the hydroxide, the polymer melt became stiff, transparent and elastomeric.

Example V To 50 g. of a copolymer of ethylene and maleic anhydride, containing 7 weight percent of copolymerized maleic anhydride and having a melt index of 8.5 g./ 10 minutes, being milled on a rubber mill at a temperature of 135 C., is added 22.8 g. of zinc monoacetate monostearate. After 15 minutes on the mill a transparent, tough, resilient polymer product is obtained having sufficient melt flow for fabrication into film by standard melt extrusion. Repeating the experimental procedure with zinc acetate an intractible resin is formed within 10 minutes of milling, preventing further milling. The resin could not be extruded into a film using standard melt extrusion.

Example Vl To 50 g. of a copolymer of ethylene and methacrylic acid, containing 10 weight percent of copolymerized methacrylic acid and having a melt index of 5.8 g./10 minutes, being milled on a rubber mill at 130 C. are added the following components in the order indicated: (a) 3.25 g. zinc oxide, (b) 11.7 g. stearic acid, and (c) 2.5 g. of acetic acid. Only after the addition of the acetic acid does the melt become clear and an increase in viscosity is observed. After 10 minutes of further milling the copolymer is removed. Although the melt index is reduced, the resulting ionic copolymer is suitable for melt fabrication.

Example VII An ethylene/methacrylic acid copolymer containing 10 percent methacrylic acid was banded on a two roll mill at C. and 3.6 weight percent of powdered 9 sodium hydroxide was added over a period of 2 minutes. Milling was continued over a period of minutes to ensure homogeneity. The ionic copolymer obtained was reduced more than tenfold in melt index and was glass clear and resilient. When extruded as a melt, the ionic copolymer could be drawn into fibers having pronounced elastic recovery.

Specific examples of the ionic copolymers of the present invention and their properties are shown in the following tables.

Table I shows physical properties of ionic copolymers obtained from an ethylene/methacrylic acid copolymer with monovalent, divalent and trivalent metal ions. The ethylene/methacrylic acid copolymer employed contained 10 weight percent of the acid and had a melt index of 5.8 g./10'=minutes. In addition to the improvements shown in the table, all these ionic copolymers exhibited excellent bend recovery which was not exhibited by the copolymer base. The tests were carried out on compression molded. sheets of the ionic copolymer.

Table IV shows the surprising melt properties of the ionic copolymers. The ionic copolymers illustrated were obtained by reacting aqueous or methanoli solutions of the crosslinking agents indicated in the table with the copolymers indicated on a two roll mill at temperatures of 150 to 200 C. until homogeneous compositions were obtained. In each instance sufficient quantities of the crosslinking agent were added to neutralize all of the acid groups. The melt index of the copolymer base and the ionic copolymer are compared and contrasted against the flow number which corresponds to the melt index, except that a temperature of 250 C. and a weight of 5000 g. is employed. Polyethylene which is crosslinked by peroxides or by ionizing radiation shows no flow for the conditions employed to measure the flow number. As can be seen from the table, at low shear stresses, i.e., under conditions at which melt index is measured, the ionic copolymers have low melt indices as compared to the base copolymers. However, at higher temperatures and under higher TABLE I Metal Cation- Na+ Li+ Sr++ Mg++ Zn++ Al++ Metal Anion CHa0- OH- OH- OHaCOO- CH3COO- OHQCOO Wt. percent of Cross linking Agent 4. 8 2. 8 9. 6 8. 4 12.8 14 Melt Index, g./10 min 5. 8 O. 03 0. 12 0. 19 0. 12 0. 09 0. Yield Point; in p.S.i 890 1, 920 1, 906 1, 954 2, 176 1, 926 1, 035 Elongation 1 in percent. 553 330 317 370 3 313 347 Ult. Tens. St. in p.S.i- 3, 400 5, 200 4,920 4, 900 5, 862 4, 315 3, 200 Stifiness 2 10, 000 27, 600 80, 000 32, 400 23, 800 30,170 15,000 Transparency (visual) Hazy Clear Clear Clear Clear Clear Clear Table II shows the effect of varying concentrations of crosslinking agent and varying concentrations of carboxylic acid groups on the solid state properties of an ethylene 'methacrylic acid copolymer employing sodium methoxide as the crosslinking agent. The term stoichiometric as employed in the table indicates such quantities of the metal ion as are necessary to form ionic links with all of the polymer carboxylate groups.

shear stresses the ionic copolymers show greatly improved flow.

Table IV further illustrates some of the requirements which must be met to obtain the ionic copolymers of the present invention. Thus, the use of zinc metal (Product No. 7) which is not ionized, does not result in any ionic crosslinking. Zinc oxide, which is ionic when dissolved 40 in water and when employed as a crosslinking agent TABLE II Percent Methacrylic Acid 5 10 1Q 10 10 16 Percent Sodium Added Excess of of of Stoichiom. Excess of Excess of Stoichiom. Stoichiom. Stoichiom. Stoichiom. Stoichiom.

Copoly-mer Base Melt Index in g./10 min" 5 5. 8 5. 8 5. 8 5.8 25 Melt; Index oi Crosslinked Polymer in g./10 min- 0.34 0. O9 0. 05 0. 02 0. 01 O. 01 Yield Point 1, 300 1, 924 1, 900 1, 900 1, 950 2, 390 Elongation 273 330 300 340 190 250 Ult. Tens. Str 3, 550 5, 200 4, 200 5, 000 3, 300 5, 500 Stiffness 14,200 27, 600 26, 200 27,200 24, 600 39, 000 Transparency--. Slight Haze Clear Clear lear Clear Clear Table III illustrates the ionic crosslinking of ethylene/ dicarboxylic acid copolymers using sodium acetate as the crosslinking agent. The table also illustrates that the crosslinking is more effective with high molecular weight copolymers than with low molecular weight copolymers, although with both a significant decrease of melt flow is obtained in the melt indexer.

(Product No. 8), results in only a partial ionic copolymer because Zinc oxide does not dissolve sufiiciently in Water or other polar solvents. Zinc stearate is not effective as a crosslinking agent (Product No. 9) to give rise to an 60 ionic copolymer because the stearate radical remains in the polymer. As can be seen from the combination of a monocarboxylic acid with a trivalent metal (Product No.

TABLE III Percent Melt Index Yield Ult. Tens Elonga- Stifiness Copoly'mer Sodium in g./10 min. Strength Strength tion in in p.s.i. Transparency Hydroxide in p.s.i. in p.s.i. lPercent l Ethylene/3 wt. percent maleic anhydride copolymer 1, 000 1, 18 1, 180 200 18, 000 Opaque.

' 1. 2 0. 1 1, 300 2, 290 17, 400 Hazy.

6. 8 1, 250 2, 000 520 19, 000 Opaque. 0. 1 1, 360 3, 100 380 23. 500 Hazy. 44. 5 1, 420 1, 800 450 24,600 Opaque. No flow 1, 440 3, 000 260 17, 000 Hazy.

9. 0 1, 320 1,800 433 15,800 0 aque. 0. 11 1, 528 1, 900 3, 000 azy.

1 1 6) a borderline improvement in the melt flow properties is obtained at higher shear stresses which is explained by the greater ionic attraction between the metal ion in a higher valence state and the carboxylic acid group. The inoperability of divalent metal ions and dicarboxylic acid were made. A one ounce machine fitted with a 78 inch cylinder was employed. The machine was operated at a cylinder temperature of 225 C. and a mold temperature of 55 C. Pressures ranging from 3000 to 6000 p.s.i. and a 30/30 second cycle were found to be adequate. The

groups (Products 21 and 17) to result in ioni copolya moldings were tough and transparent and reproduced the mers of the present invention is also illustrated. These finest details of the molds employed. Polyethylene of the polymers are believed to have such strong ionic bonds same melt index did not fill the molds under these conthat they in effect act like regularly crosslinked polyditions. olefins. The table further illustrates the wide variety of 10 Example XI metal ions which are suitable crosshnking agents. Addr- U i h i i copolymer f E l VIII, fo o n e tionally, the table also shows that the presence of a third B t R d b l were prepared Th resin was monomer does not interfere in the formation of the ionic truded through a two inch extruder fitted with a crosscopolymers of the present invention. head tubing die (D. inch, ID. /2 inch) and blown TABLE IV C l I Fl Product No. Com0nomer(s) Comonomer Crosslinking Reagent B2128 (.lopg l y cr Nuri'ila er Cone. g./ min. M.I. in in g./10

g./10 min. min

1 Methacrylic acid 10. 0 Sodium hydroxide 6. 3 0.03

10.0 Lithium hydroxide 5.8 0.12 10.0 Zinc acetate 5.8 0.13 10.0 Magnesium acetate 5. 8 0.107 10. 0 Aluminum hydroxide 5. 8 0. 2 10. 0 Zinc metal 5. 8 6. 5 10. 0 Zinc oxide 5. 8 0.98 10. 0 Zinc stearate 5. 8 4. 8 10. 0 Nickel acetate. 5.8 0.25 10.0 Cobalt acetate. 5. 8 0.13 10. 0 Sodium carbonat 5.8 0.05 10. 0 Tin acetate 5.8 0.17 1". 0 Sodium methoxide 5. 8 0.03 10. 0 Sodium formate 5. 8 0.08 6 Sodium hydroxide 9.0 0.11 6 Strontium hydroxide. 9. 0 6 Zinc oxide 9. 0 3 Sodium hydroxide- 300 3 Lithium hydroxide 300 0. 008 3 Zinc acetate 300 til? it t t t 2? 8'1? 3. CSlllTlfiC l 4 Methyl methacrylate/methacrylic acid /5 sod i um hydro idei 3. 6 0. 16 Styrene/methacrylic acid 15/5 0 6.0 0.13

1 No flow.

Example VIII into a bottle using a 4 ounce Boston Round bottle mold. An ethylene/methacrylic acid copolymer containing 10 rtrhqresm was heatgd to m g}; 5 3 5 percent of methacrylic acid was ionically crosslinked with ruslonffsfcrew Spec es 0 tame sodium hydroxide until 76 percent of the carboxyl groups were S 1 transparfint an fleet y puma had been neutralized. The melt index of the resulting poly- 5 Example XII mer was 0.65 g./ 10 minutes. This resin was extruded through a one inch extruder equipped with a tubular film 2 i f g l i coptalmng die and take-off. The ionic copolymer was extruded into a 0 mg acry'lc acl lomca 1y crosshn ed Wlth Sodl- 0.5 mil film using a 225 C. temperature for the extruder um hylqroglde fi of the-carboxyl groups had-been barrel and a 250 C. temperature for the die. The result- 3E i 238? g i'g :2 ing film was completely haze-free and transparent. Dart of a f n t d 1 1 a drop test gave a value of 375 at 0.5 mil thickness Comm o lama y Omen e p0 ypropy nor to arable values for olyeth g' 92 /cc 50 coating the polypropylene film surface Was sub ected to g Pneumatic p z was gi; A a p y p a flame treatment with a substantially neutral flame, folfl'lalate ester has a valu of 5 /mil In addi lovl/zmg the'procedure described in U.S. Patent 2,648,097.

. tion to its excellent impact resistance, this film displayed gf s g g i g 2; g gg f was meflt marked shrinkage when immersed in boiling water making .t g? Com 2 i y i refsm it ideal for many packaging applications. X-ray examinah p l e ea Se or tion showed the film to be biaxially oriented t I lzlxlany o-nented polypropylene film bearing a one mll thick coating of the ionic copolymer and a similar Example IX thickness coating of polyethylene resin are shown in Using the ionic copolymer of Example VIII, a 30 mil abluagsform bdelow.HAll heat seals were made at 10 p.s.i. wire coating was produced on #14 copper wire. A three an Secon dwe tune and One-quarter inch Davis-Standard wire coater fitted with an 0.124 inch tapered pressure die was employed. Heat Seal Strength (g./in.) Extrusion was carried out at 450 ft./minute using temig gf perature settings of 475 F. on the barrel and 490 F. turn?" 0. Ionic on the die and quench temperatures of 200 F. to 72 F. 32 3;? Coated A very smooth, glassy, coating was obtained displaying excellent toughness and electrical properties. Polyethylene 100 900 having the same melt index could not be extruded into a 95 600 50 continuous smooth wire coating under these conditions. 90 250 (l) Example X SeaL Using the ionic copolymer of Example VIII injection Strong heat seal bonds were obtained on the ionic co molded combs, cham links, gears, 0011 forms and chips 75 polymer coated film at sealing temperatures as high as 140 C. The broad heat .sealing temperature range and particularly the ability of the ionic copolymer coated film to be sealed at low temperatures as well as at higher temperatures makes the ionic copolymer well suited for use on films to be applied in high speed wrapping and packaging operations and for films which are dimensionally unstable at elevated temperatures such as films which are heat shrinkable at about 100 C.

Physical property measurements show that elongation of the ionic copolymer coated polypropylene film is greater than is the elongation of the base film without a coating. This is of advantage in various packaging and forming operations wherein the film may be subjected to considerable stress in localized areas. Further, the ionic copolymer coated fihns are more resistant to oil penetration and to abrasion than corresponding films coated with polyethylene resin.

Example XIII An ethylene-methacrylic acid copolymer containing 10% of methacrylic acid, ionically crosslinked with sodium hydroxide until 31% of the carboxyl groups had been neutralized and having a melt index of 1.1 g./l min. at 190 C. was melt coated at 290 C. into a onemil thick coating on a surface of a biaxially oriented polyethylene terephthalate film which had been flame treated as in Example XH. The coated film showed a heat seal value (coating-to-coating) of 1000 grams/inch when sealed at 100 C. at p.-s.i. and 0.25 second dwell time. For comparison, the same polyethylene terephthalate film coated with a two-mil thick coating of polyethylene resin (Alathon 1550) and heat sealed under the same conditions showed a heat seal strength of only 28 grams/inch.

Example XIV for adherability by the electrical discharge treatment described in U.S. Patent 3,018,189. The ionic copolymer coated film showed a heat seal value of 1000 grams/inch on heat seals made'at 100 C. at 10 p.s.i. and 0.25 second dwell time. A control film coated with-polyethylene resin showed substantially no seal strength when heat sealed under the same conditions.

Example XV An ethylene/methacrylic acid copolymer containing 10% of methacrylic acid, ionically crosslinked with sodium hydroxide until 70% of the carboxyl groups had been neutralized and having a melt index of 1.0 g./ 10 minutes at 190 C. was melt coated as a one-mil thick coating on a surface of a one-mil thick base film of polyhexamethylene adipamide, the surface of which had been flame treated as described in Example XII. The coated film when sealed at 100 C. at 10 psi. for 0.25 second showed a heat seal value of 1000 grams/inch. The same base film coated with a polyethylene resin (Alathon 155 0) and sealed under the same conditions showed a seal strength of only 25 grams/inch.

The foregoing examples and experimental data have demonstrated the surprising combination of improvement in solid state properties and retention of melt properties obtained by the compositions of the present invention. One of the more apparent improvements obtained is that of transparency. Hydrocarbon polymers are generally not transparent in all but exceptionally thin forms and even there special techniques such as quenching and drawing must be employed to obtain a measure of transparency. The copolymers of the pres ent invention, however, can be made to be transparent even in thick molded sections. Another solid state property which is markedly improved by ionic crosslinking is the resilience or bend recovery of the copolymer. In contrast to hydrocarbon polymers which have a slow and incomplete recovery from bend, the copolymers of the present invention snap back when deformed and assume their original shape. The improvement obtained in tensile properties and stiffness is apparent from the data presented in the tables. In this respect the copolymers of the present invention exhibit greatly surprising properties. In contrast to peroxide-crosslinked polyethylene where the stiffness is decreased by crosslinking, the ionic copolymers exhibit even greater stiffness and rigidity than the unmodified base polymer. Other solid state properties improved by ionic crosslinking are toughness and stress-crack resistance. The impact strength of thin films made from ionic copolymers is equal to and better than that of polyterephthalate films which are considered the toughest plastic films commercially available. Tests designed to measure stress-crack resistance of hydrocarbon polymers using detergents commorfly used in such tests failed to result in failures and, thus, the ionic copolymers are considered to be free from stress-crackmg.

The ionic copolymers of the present invention also exhibit highly surprising rheological properties. Thus, although having extremely low melt indices, which would indicate that the ionic copolymers are not melt fabricable, the opposite is true in that the ionic copolymers can be melt extruded, injection molded and compression molded with case. This is explained, of course, by the difference in shear stress exerted on the melt in a melt indexer and in an extruder, for example. At low shear stresses the high melt strength of the polymer results in low melt flow. However, once this is overcome by a higher shear stress, the ionic copolymers flow readily. .The combination of high melt strength at low shear stresses and good melt flow at high shear stresses is highlydesirable in all applications requiring forming of the melt subsequent to extrusion such as in bottle blowing in which an extruded parison is blown into a bottle and in thermoforming in which molten sheet is forced against a mold by means of a vacuum. In both these fabrication techniques, the polymer melt becomes unsupported during some part of the fabrication cycle and it is, therefore, highly desirable that'the polymer melt have a highmelt strength and a good retention of shape. Similarly, the ionic copolymers of the present invention are extremely useful for the preparation of foams in that they overcome the extremely low strength of the foamed but not yet solidified polymer which has been a major problem in form extrusion and which frequently has caused the collapse of the foam.

An additional advantage that can be obtained in the copolymers of the present invention is coloration. By proper choice of metal ions and combinations of metal ions many colors can be produced in the ionic copolymers. This method coloration has advantages over polymer dyeing in that dyes have a tendency to exude from hydrocarbon polymer-s and frequently are not compatible therewith. It also has an advantage over coloration by pigmentation in that the coloration is more uniform and even, particularly in light colors. Furthermore, colored compositions can be made transparent.

The ionic copolymers may be modified, if desired, by the addition of antioxidants, stabilizers, fillers and other additives commonly employed in hydrocarbon polymers. The ionic copolymers can be blended with each other and all hydrocarbon polymers in general to achieve improvement in properties of those polymers with which the ionic copolymers are blended. It is generally preferred to employ additives which do not interfere with the ionic crosslinks, i.e., compounds which do not meet the requirement of crosslinking compounds set forth above 115 or if ionic in nature to employ such metal ions as would complement the metal ions used in the crosslinking. Generally, however, additives do not interfere with the ionic crosslinks since they are not of the type which would result in metal ions and, furthermore, are employed in very small quantities. If desirable, the copolymers of the present invention can be blended with other hydrocarbon polymers to meet particular needs of an application. In order to realize the surprising properties obtained in ionic copolymers, it is essential that the ionic copolymers do not contain any significant number of covalent crosslinks, since the latter would obscure and overshadow the ionic crosslinking.

The high molecular Weight ionic copolymers of the present invention can be extruded into films of excellent clarity, fibers of outstanding elasticity and resilience, pipes with superior stress-crack resistance, wire coatings with improved cut-through resistance and good dielectric properties despite the presence of metal ions, and foamed sheets; they can be further injection molded into intricate shapes and closely retain the dimension of the mold; they can be vacuum formed, blow molded and compression molded with greater ease and better properties than linear hydrocarbon polymers. Ionic copolymers can, furthermore, be drawn and uniaxially or biaxially oriented. Ionic copolymer surfaces, are printable and adhere well to adhesives commercially available. Thus, they can be laminated to paper, metal foil and other plastic surfaces. The adhesion of the ionic copolymer is so good that they themselves can be employed as adhesives. Low molecular weight ionic copolymers, particularly are useful for such purposes. Many other uses and modifications of the ionic copolymers of the present invention will be apparent from the foregoing description and it is not intended to exclude such from the scope of this invention.

What is claimed is:

1. An article of manufacture comprising a heat-sealable film structure including a base layer of a selfsupporting fiim of organic thermoplastic polymeric material having a heat-sealable coating on at least one surface thereof of an ionic copolymer selected from the class consisting of direct copolymers of oc-olefins having the general formula RCH=CH wherein R is a radical selected from the class consisting of hydrogen and alkyl radicals having from 1 to 8 carbon atoms, the olefin content of said copolymer being at least 50 mol percent based upon said copolymer,

and an alpha, beta-ethylenically unsaturated monocarboxylic acid, the acid monomer content of said copolymer being from 5 to mol percent based upon the copolymer,

said copolymer having a melt-index between about 0.5 and about 40 and containing uniformly distributed throughout said copolymer a metal ion having an ionized valence of 1 to 3 inclusive, wherein at least 10 percent of said monovalent carboxylic acid copolymer are neutralized by said metal ion and exist in an ionic state.

2. The article of manufacture of claim 1 wherein said base layer of a self-supporting film structure is a polyolefin.

3. The article of manufacture of claim 2 wherein the polyolefin film structure is biaxially oriented.

4. The article of manufacture of claim 1 wherein the base layer of a self-supporting film structure is biaxially oriented polyethylene terephthalate.

5. The article of manufacture of claim 1 wherein said base layer of a self-supporting film structure is a polyamide.

6. The article of manufacture of claim 1 wherein said heat-scalable coating of an ionic copolymer is character ized by an acid monomer content of between about 10 and about 20 percent by weight, based upon the total weight of said ionic copolymer.

7. The article of manufacture of claim 1 wherein the a-olefin in said ionic copolymer coating is ethylene.

8. The article of manufacture of claim 1 wherein said monocarboxylic acid in said ionic copolymer coating is methacrylic acid.

References Cited UNITED STATES PATENTS WILLIAM D. MARTIN, Primary Examiner.

W. D. HERRICK, Assistant Examiner. 

1. AN ARTICLE OF MANUFACTURE COMPRISING A HEAT-SEALABLE FILM STRUCTURE INCLUDING A BASE LAYER OF A SELFSUPPORTING FILM OF ORGANIC THERMOPLASTIC POLYMERIC MATERIAL HAVING A HEAT-SEALABLE COATING ON AT LEAST ONE SURFACE THEREOF OF AN IONIC COPOLYMER SELECTED FROM THE CLASS CONSISTING OF DIRECT COPOLYMERS OF A-OLEFINS HAVING THE GENERAL FORMULA RCH=CH2 WHEREIN R IS A RADICAL SELECTED FROM THE CLASS CONSISTING OF HYDROGEN AND ALKYL RADICALS HAVING FROM 1 TO 8 CARBON ATOMS, THE OLEFIN CONTENT OF SAID COPOLYMER BEING AT LEAST 50 MIL PERCENT BASED UPON SAID COPOLYMER, AND AN ALPHA, BETA-ETHYLENICALLY UNSATURATED MONOCARBOXYLIC ACID, THE ACID MONOMER CONTENT OF SAID COPOLYMER BEING FROM 5 TO 25 MOL PERCENT BASED UPON THE COPOLYMER, SAID COPOLYMER HAVING A MELT-INDEX BETWEEN ABOUT 0.5 AND ABOUT 40 AND CONTAINING UNIFORMLY DISTRIBUTED THROUGHOUT SAID COPOLYMER A METAL ION HAVING AN IONIZED VALENCE OF 1 TO 3INCLUSIVE, WHEREIN AT LEAST 10 PERCENT OF SAID MONOVALENT CARBOXYLIC ACID COPOLYMER ARE NEUTRALIZED BY SAID METAL ION AND EXIST IN AN IONIC STATE. 